Build the USS CONSTITUTION the World’S Oldest Commissioned Naval Vessel Afloat 11 Build the USS CONSTITUTION Contents STAGE PAGE 101 the Mainmast 223

Build the USS CONSTITUTION The world’s oldest commissioned naval vessel afloat 11 Build the USS CONSTITUTION Contents STAGE PAGE 101 The mainmast 223

102 Mainmast yards and fittings 225

103 Yards and fittings 227

104 Rigging and fittings 229

105 The mizzenmast 231

106 Yards and fittings 233

107 Booms and fittings 235

108 Rigging and fittings 237

109 Deadeyes and blocks 239

110 Sails 241

Editorial and design by Continuo Creative, 39-41 North Road, London N7 9DP. Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE. Published in the USA by De Agostini Publishing USA, Inc.,121 E. Calhoun Street, Woodstock, IL 60098. All rights reserved © 2017

Warning: Not suitable for children under the age of 14. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown. USS CONSTITUTION STAGE: 101 The mainmast C

81. Mainmast 97. Main top 88. Rubbing paunch 106. Main topmast 89. Hounds 107. Hounds 91 and 108. Bibs 112. Main topgallant mast 92. Trestletrees 113 and 115. Hounds 93. Crosstrees 132 and 135. Jaws 94. Chock Mainmast plan 101C Retrieve the head rails from Stage 62. 95. Bolsters Remove them from the fret, sand them smooth and then paint them black. Test-fit from the starboard cathead knee to the underside of the bulwark (see next step), and adjust the fit 112 106 81 if necessary.

93-94-95 D

97 108

135 91 132 92 88-89-107-113-115

101D Glue two lengths of brass rod, painted A 101A Retrieve the two white, along the edges of the rail. Glue the first bulwarks (Stage 100) and glue rail into place, then repeat on the port side of them into postition at the bow. the bow.

B 101B Cut two lengths of brass rod to fit the underside of the knees of the catheads, as shown, and paint them white. Glue into place on the starboard cathead, and then repeat the process on the port side. 101E Make a loop at one end of a brass rod, to create the ring (12) according to the bowsprit plan.

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F 101I Now begin to shape the I spritsail yard (20). Cut the 5mm dowel from Stage 95 to match the length on the plan. The ends are stepped, as shown here, so use a file to achieve this.

101F Then create the boom iron (13) with a G brass rod, following the bowsprit plan.

101G Drill a hole in the bowsprit cap, as indicated on the plan. Glue the flying jibboom (3) into the ring (12). Then glue 101J Use a sanding block to the ring into the hole in the cap (arrowed). taper the yard to match the one Secure the flying jibboom to the end of the shown on the plan. jibboom using the boom iron (13). H J

101H Here is how the flying K jibboom should look when fitted correctly.

101K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.

224 USS CONSTITUTION STAGE: 102 Mainmast yards and fittings C

83. Brackets 101. Handrail 90. Fairlead 109. Main topmast crosstrees 104. Guides 116. Main yard 111. Fairleads 127. Main topyard B 85. Cleats 133 and 136. Studdingsail booms 98. Ribs C. Blocks 129. Cleats E. Deadeyes 99. Edge G. Blocks 102C Glue the two B chainwales to the sides of 127 116 E the hull, near the bow, just below the spar deck 133-136 109 gun ports, as shown. The two should be aligned 90-99-104 on either side of the ship.

102D Glue the remaining chainwales, A and C, to the aft and amidships areas of the hull, just below the spar deck gun ports. Make sure that they are aligned. D C G 83-85-98-101 111-129

A A C A

C E

102A This diagram shows the location of the holes in the chainwales, which you will assemble and fit in this stage.

B 0.1mm A 102B Retrieve some 2 x 6 B x 300mm ramin strips. Cut two 160mm lengths (C), two C 80mm 140mm (B) and two 80mm (A). Paint all of the lengths 140mm black, and then drill 0.1mm holes in them according to 160mm the diagram in Step A. These 102E Glue and rig two of the longer cannons to are the chainwales. the spar deck, as shown.

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102F Now drill four holes in F I the jibboom, two on either B side, as shown here and on the plan. 1mm

19 E

102G Create the sling (19) G 102I Tie the two blocks to the from 1mm brass rod to fit end of the flying jibboom, as around a 5mm deadeye (F), shown above and on the plan. so that the ends bend inwards Then prepare a 4mm deadeye and fit into the holes made in (E) with a brown thread sling the previous step, as shown. (19), and tie it to the end of Repeat this to create and fit the jibboom. the second set. 19 F

H J

102J Prepare the remaining C deadeyes and blocks for the B bowsprit, according to the plan. Follow this photo and the plan to fit them all into place.

102H Take two 4mm blocks K (C) and tie a line (B) around each. To do this; tie a simple reef knot around the block at one end of the line, to avoid wastage. Apply a drop of glue to the knot, and cut away the short length of the line. 102K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.

226 USS CONSTITUTION STAGE: 103 Yards and fittings C

114. Main topgallant mast crosstrees 121. Boom irons 117 and 128. Battens 130. Boom irons 118. Sling cleats 134. Main topgallant yard 120. Boom irons 138. Main royal yard 103C Retrieve two anchors, two 8mm rings 138 and 1.5mm brown thread. Open the rings and 134 117-128 pass through the hole at the top of the anchor shank, then close again. Pass some brown thread through the ring and double it back on itself. Use 0.15mm thread to create the seizing around the doubled brown thread, and fix with glue. Pass one of the flukes of each anchor 130 through the netting in the midships port. Create a coil with the other ends of the brown thread, fix it with glue and leave it to dry, then 120 place it on the deck.

121 D 118 114

A 103A Take a 2 x 6mm strip and cut two 22mm lengths from 22mm it. Use a file to shape the two pieces to match those shown 103D Cut two 22mm lengths of 10mm dowel. in the photo. The notch in the File about a third of the width flat, as shown, 22mm middle should be 4mm wide then paint both pieces black. They should and 2mm deep. Paint both be identical. pieces black. 10mm E

103B Glue the two pieces on B either side of the hull, on the outside of the bulwarks. They should each be 10mm forward of the rectangular port, and 2mm below the gunwale.

10mm 103E Glue each piece underneath the port below the platform, as shown, on either side of the hull. 227 USS CONSTITUTION

F H C 23 20

21 22

103F Take the spritsail yard I 103H Fit the blocks and (20), and paint it with wood rigging to the spritsail yard, stain. Mark the points on the according to the plan. yard where eyepins are shown on the plan.

103I Using a round file, open up the hole at the bow into which the bowsprit will fit.

G J

20 A 103J Insert the end of the bowsprit into the hole at the bow, as shown. A

103G Drill a 1mm hole at K each point marked in the previous step. Cut the shanks off the eyepins (A), and then glue the eyepins into the holes.

103K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.

228 USS CONSTITUTION STAGE: 104 Rigging and fittings C

119. Sling 152. Slings 22mm 123. Stirrups 176 and 182. Footropes 125. Braces B. Lines 126. Parrels C. Blocks 137 and 139. Footropes D. Double blocks 141. Bindings E. Deadeyes 104C Glue the first davit into position, inserting G. Blocks the pins into the holes made in the previous step. Then repeat Steps A and B to fit the remaining three davits, to the positions shown 119-123-125 B G E on both sides of the hull. 126-137-139 141-152 176-182 D 113mm

A 104A Cut a 4mm section of the 104D Cut two 113mm lengths of 2 x 2mm raised wale above the starboard wooden strip. Sand the ends, and then paint quarter gallery. Test-fit one of both lengths white. Glue the lengths to the 4mm the davits (Stages 87 and 88) davits, as shown. into this gap, and enlarge the gap if necessary. E

B 1.5mm 104B Using a 1.5mm bit, drill 24 two holes in the bulwark to correspond with the pins on the inside of the davit.

104E Take the 10mm dowel (Stage 97) and place it on the foremast plan. Cut the dowel to match the length of the foremast (24) shown on the plan.

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104F Retrieve the mast cap F fret received with Stage 95, then remove the foremast cap (43) from it. Remove the two pieces from the holes in the cap, and then sand it smooth. 104I Shape the end of the mast to match the square marked in the previous step. 43 The square needs to be deep enough to fit inside the cap (see Step J).

104G Use a sanding block to G I taper the foremast to match the plan.

24 24

H J 104J Test-fit the end of the foremast into the square hole 43 in the mast cap. Adjust the fit if necessary. Do not glue the parts just yet.

104H Place the square hole K 104K This stage is now of the cap over the centre complete. Store any of the thinner end of the materials that you haven’t foremast. Mark the edge used, because they will be of the hole onto the end of needed in future stages. the mast.

230 USS CONSTITUTION STAGE: 105 The mizzenmast C 38

140. Mizzenmast 151. Bolsters 142. Rubbing paunch 153. Foretop 143 and 173. Hounds 163. Foretopmast 145. Spencer mast 164, 169 and 171. Hounds 147 and 165. Bibs 181. Jaws 148. Trestletrees E. Deadeyes 149. Chock Mizzenmast plan 105C Use 2 x 2mm ramin strips to make the 150. Crosstrees Rigging plan foretop ribs (38), according to the plan. Make sure they don’t obstruct the central hole at all, 140 and then glue them into place. You may find it E helpful to number them. 163 145

D 153 165

181 147 142-143-164 148 149-150-151 169-171-173 1mm

105A Remove the foretop (37) A 105D Drill five 1mm holes in each side of the from the fret received with foretop, just in from the rims. Stage 97. Smooth with a piece of fine sandpaper.

37 105E Now take the 8mm dowel (Stage 97), and begin to create the foretopmast (45). Cut it to the correct length before tapering it.

105B Create the foretop rims B 39 E (39) using a 2 x 4mm ramin strip. You will need to bend the rim slightly at the front.

39 45

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F 105I Retrieve the dummy I guns supplied in the previous stages. Test-fit one of them in the hole drilled in the previous step. Enlarge the hole if necessary, and then glue the gun into place.

105F Remove the foretopmast cap (51) from G the fret. Prepare the cap, and shape the top 24 37 of the foretopmast to fit the square hole in it.

105G Now prepare the foretopgallant mast (53) using the 6mm dowel from Stage 97, according to 45 105J Repeat Steps H and I in the plan. Keep all parts of the foremast together. 53 the ports along the rest of the gun deck. Complete one side, and then repeat on the other.

H J

2mm

105H Drill a 2mm-wide hole in the centre of the aft gun K 105K This stage is now deck port, as shown. complete. Store any materials that you haven’t used, because they will be needed in future stages.

232 USS CONSTITUTION STAGE: 106 Yards and fittings C

154. Ribs 168. Mizzen topgallant mast 155. Mizzentop rims 172. Mizzen yard 157. Handrail 180. Mizzen topyard 160, 177 and 190. Cleats 183. Mizzen topgallant yard 161. Guides 185. Mizzen royal yard 166. Mizzen topmast crosstrees C. Blocks 106C Now recover the foretop, and glue the crosstrees to the underside of it, as shown. 180 168 183-185 172 166 155-161 D 1mm

154-157-160 177-190

106D Drill four 1mm holes (arrowed) along the 106A Remove the four A inside of the rear rim, for the stanchions (40). trestletrees (32) from the fret received with Stage 97. Smooth the parts with sandpaper.

32 106E Create the stanchions according to the plan, and then glue them into the holes in the foretop made in the previous step.

B 106B Use 3 x 3mm ramin E 34 strips to create the crosstrees (33) and the chock (34). Use the photo here and the plan to assemble the crosstrees, 40 trestletrees and chock. When the glue has dried, curve the undersides of the trestletrees, as shown in the inset. 32 33

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F H 106H Retrieve the gun port doors received in previous stages, and paint them black. 42 When they are dry, paint one side white, as shown.

106F Now take the netting I 106I Glue the upper doors received with previous stages, (with holes) to the tops of and cut a 50 x 10mm strip the gun ports, against the from it. frame, and the lower doors (no holes) flat against the hull underneath the ports, as shown.

G J 41

106G Glue the netting to the K 106J Repeat this for the rest aft side of the stanchions. of the gun deck ports on both Then create the handrail (41) side of the hull. with some 2 x 2mm strip, and glue it, centred, onto the top of the stanchions.

106K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.

234 USS CONSTITUTION STAGE: 107 Booms and fittings C

146. Sail hoops 70. Sail hoops 29 187. Spanker boom C. Blocks 28 191. Spanker gaff D. Double blocks

187-191 70 107C Now prepare and glue the two hounds 146 (29) into place on the foremast, on each side of the rubbing paunch.

D D

107A Glue the foretop to A 107D Remove the two bibs (31) from the fret the foremast in the position received with Stage 97. Smooth them with shown on the plan. Then, use sandpaper, and then glue them to the side of the 0.8mm brown thread to create foremast, under the foretop. the foremast bindings (25). These should each be a single loop around the mast, secured by glue. 25

107E Use a length of 2 x 4mm ramin strip to create the fairlead (30), as shown in the inset. Glue it to the foremast in the position shown here and on the plan.

B E 107B When the glue has dried, 28 30 cut away the sections of the bindings where the rubbing paunch (28) and the hounds (29) will go. Glue the rubbing paunch into place, pressed flat against the mast.

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107F Cut four 5mm lengths F I of 2 x 2mm strip to make the brackets (26). Drill a 1mm hole in each bracket. Cut two 30mm lengths of 1mm brass rod to 27 create the struts (27). Glue the brackets onto the the ends of the struts, and then glue the assemblies to the mast. 26

107G Here is how the foremast G 107I Drill more holes in a line forward, should look at this stage. as shown, then glue more painted rivets into them.

107J Continue forward, drilling six more holes and fitting rivets into them. H J

10mm diam. 2mm

107H Retrieve the rivets, K 107K This stage is now and paint their heads black. complete. Store any Using a 2mm bit, drill holes materials that you haven’t in the hull under the gun used, because they will be deck gun ports, as shown. needed in future stages. Glue a rivet into each of these holes.

236 USS CONSTITUTION STAGE: 108 C Rigging and fittings 44 43

144. Saddle E. Deadeyes 170. Mizzen topgallant crosstrees F. Deadeyes 174. Stirrups 1. Jib guy 175. Sling 3. Jibstay 178. Parrels 5. Bobstays 179. Braces 7. Foremast shrouds 108C Now prepare the foremast cap and guide 184 and 186. Footropes 10. Mainmast shrouds (43 and 44). Cut two 15mm lengths of 2 x 4mm 193. Braces 11. Mizzenmast shrouds strip, and glue them together over the square B. Lines 12. Gammoning hole of the mast cap. File a groove along the centre of them, as shown. 174-175-178-179 170 184-186-193 B D 1mm 1-3-5-7-10-11-12

144 E 45 F

108A Apply the remaining A 108D Glue the foremast cap onto the top of the bindings (25) to the upper part foremast. Paint the foretopmast (45) with wood of the foremast. 25 stain. Drill a 1mm hole through the bottom of the foretopmast for the fid (46), then glue the foretopmast into place.

108E Cut a 14mm length of 1mm brass rod to create the fid (46). Insert the fid through the hole at the bottom of the foretopmast.

B 108B To create the cleats E (47), take a 2 x 2mm strip and 47 cut two 5mm lengths from it. Shape the two lengths to match those on the plan, and then glue them into place.

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F 108I Cut 12 7mm lengths of 1 I x 3mm strip. Round the edges of the pieces, as shown, then paint the pieces black.

108F Here is how the foremast should look G with the foretopmast in place.

108J Glue six pieces onto 108G Cut 18 9mm lengths of 2 x 2mm strip and each side of the hull, in the 1 x 3mm strip. Glue the lengths together to positions indicated. They create the steps, as shown here. should follow the same line as 9mm the rivets.

H J

108H Paint the 18 steps K 108K This stage is now white. Glue nine on either complete. Store any side of the hull, below the materials that you haven’t midships port, as shown, used, because they will be spacing them 1mm apart. needed in future stages.

238 USS CONSTITUTION STAGE: 109 Deadeyes and blocks C 50

C. Blocks E. Deadeyes D. Double blocks F. Deadeyes 49

E 49 C 109C Glue the two bibs either side of the F topmast, aligning the tops of them with the tops of the hounds. Then glue the topmast crosstrees (50) onto the top of the bibs and hounds.

D D 51

109A Cut five 18mm lengths of A 1 x 5mm wooden strip to create the hounds (48). Glue them Prepare the the fore topmast cap (51) around the foretopmast, as 48 109D received with Stage 95. Glue the cap onto the shown here and on the plan. top of the foretopmast.

E 53

109B Remove the two bibs B (49) from the fret received with Stage 97, and smooth them with sandpaper.

109E Test-fit the foretopgallant mast (53) through the mast cap and into the crosstrees. Adjust the fit if necessary, and then paint the mast with wood stain. Refit the mast, and glue 49 it into place.

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F H 109H Drill 10 holes in a 52 line along the bottom of the 0mm 1 10mm transom, as indicated, with 10mm 10mm a 0.75mm bit. Then drill 15mm another two holes, near the top of the rudder.

109F Create the two fairleads I 109I Retrieve 12 eyepins, (52) with a 2 x 2mm strip. Glue and the chain received with the two fairleads underneath Stage 45. Cut the chain into the cap. two 128mm lengths, then loop 22mm eyepins through the chain links at the points indicated. 22mm 22mm 22mm 40mm

G 56 J 55 54

109G Using a 1 x 5mm strip, K 109J Glue the eyepins into prepare the remaining the holes drilled in Step H, foremast hounds (54 and as shown. 56), according to the plan. Glue the foretopgallant mast crosstrees into place, then glue the hounds to the mast.

109K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.

240 USS CONSTITUTION STAGE: 110 C Sails B

C C

V1. Spritsail V2. Flying jib C D V2 D C

110C Paint the two remaining sections of the foremast white, and when dry, fit the other parts of the rigging and blocks, as shown.

110A Paint the foremast white, A from the top of the mast cap D down. When dry, attach the slings (36) and the single and 110D Test-fit the foremast into the collar. double blocks (C and D). 36 Enlarge it with a round file if necessary.

C D 110E Insert the foremast into the collar. Apply glue to the contact points between the mast and the collar.

B 110B Now paint from under E the topmast hounds to the D top of the mast cap white, as shown. Then attach the double blocks to the cap and the topmast crosstrees.

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110F Prepare the fore yard F (57), the fore topyard (68), 57 the fore topgallant yard (75) and the fore royal yard (79), following the plan.

110I Repeat Step H to fit seven more 5mm deadeyes (F), then repeat it to fit two 4mm deadeyes (E) into the last two holes in 79 75 68 the chainwale.

110G Wrap a length of G I 0.5mm brass wire around a deadeye (F), then cut it, E leaving a 40mm length, as shown. Make sure one of the 40mm holes is positioned next to the twist (inset).

H F J 110J Now fit the deadeyes to the main and mizzen chainwales. The last two E deadeyes of each should be E 4mm (E). 3mm 5mm

110H Pass the end of the wire through K 110K This stage is now the first hole in the foremast chainwales complete. Store any aft of the cannon, as shown. The deadeye materials that you haven’t should rest on the wale. Hammer a nail used, because they will be into the hull, 3mm from the bottom of needed in future stages. the white strakes. Pull the wire tight, and wrap it around the nail once. Fit another nail 5mm below the white strakes, and wrap the wire around this as well. Hammer the nails into the hull until they are up against the wire, then trim any excess wire.

242